NEW SIMULATION

This dialog enables the user to define a new simulation prior to displaying the AutoSetup interface. First, select AUTOSETUP from the SETUP menu. If AutoSetup is defined in the existing database, the program will automatically display the AutoSetup interface. Otherwise, the program will automatically display the New Simulation window illustrated in Figure 8.2.2. The user must define the setting in New Simulation window.

 

NOTE: The user is only allowed to set one AutoSetup project in each database.

newsimu

Figure 8.2.2  New Simulation window

 

8.2.1.1       SIMULATION TYPE

There are two simulation types supported in AutoSetup. One is sheet forming, which includes sheet forming and sheet hydroforming. The other one is tubular hydroforming.

 

8.2.1.2       BLANK THICKNESS

At the beginning of each new setup, the user shall key in the desired blank thickness. This value will be automatically set in Blank page. The user may modify the blank thickness in Blank page. Default blank thickness is 1.0 (mm).

 

8.2.1.3       PROCESS

As shown in Figure 8.2.3, the AutoSetup includes 8 ordinary process templates.

 

Figure 8.2.3  Process

 

GRAVITY: gravity loading simulation

CRASH FORM: forming process using upper and lower tools.

SINGLE ACTION: air draw or inverted toggle draw process using die, punch and binder.

DOUBLE ACTION: toggle draw process using die, punch, upper and lower binders.

TRIPLE ACTION: forming process using multiple pieces of tooling.

SPRINGBACK: springback simulation.

TRIMMING: trimming simulation.

SUPERPLASTIC FORMING: superplastic forming simulation

 

8.2.1.4       ORIGINAL TOOL GEOMETRY

In this field, the user chooses to perform stamping simulation using either CONTACT OFFSET algorithm or physical tool geometry. The user may turn on the radio button of either Upper or Lower option if he/she selected the CONTACT OFFSET algorithm. As illustrated in Figure 8.2.4(a), the contact interfaces of both punch and binder are offset by (2.2*t) if the Upper option is chosen. Similarly, the contact interfaces of die is offset by (2.2*t) if the Lower option is chosen, as illustrated in Figure 8.2.4(b).

 

NOTE: The geometry of punch and binder are duplicated from the die geometry if CONTACT OFFSET algorithm is adopted in stamping simulation.

 

(a) Using DIE geometry as reference for contact offset

(b) Using PUNCH geometry as reference for contact offset

 

(c) Using both DIE & PUNCH physical geometry

Figure 8.2.4  Blank Reference Surface

If the user chooses to perform the stamping simulation using physical tool geometry, he/she should turn on the radio button of Upper&Lower illustrated in Figure 8.2.2. It is recommended to perform stamping simulation using physical tool geometry if springback is primary concern.